US4742865A - Method of controlling an energy recovery system - Google Patents

Method of controlling an energy recovery system Download PDF

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US4742865A
US4742865A US06/730,557 US73055785A US4742865A US 4742865 A US4742865 A US 4742865A US 73055785 A US73055785 A US 73055785A US 4742865 A US4742865 A US 4742865A
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fluid
accumulator tank
heat exchanger
temperature
accordance
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US06/730,557
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Jacob Weitman
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
    • F28D21/00—Heat-exchange apparatus not covered by any of the groups F28D1/00 - F28D20/00
    • F28D21/0001—Recuperative heat exchangers
    • F28D21/0012—Recuperative heat exchangers the heat being recuperated from waste water or from condensates
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06F—LAUNDERING, DRYING, IRONING, PRESSING OR FOLDING TEXTILE ARTICLES
    • D06F33/00—Control of operations performed in washing machines or washer-dryers 
    • D06F33/30—Control of washing machines characterised by the purpose or target of the control 
    • D06F33/46—Control of the energy or water consumption
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24D—DOMESTIC- OR SPACE-HEATING SYSTEMS, e.g. CENTRAL HEATING SYSTEMS; DOMESTIC HOT-WATER SUPPLY SYSTEMS; ELEMENTS OR COMPONENTS THEREFOR
    • F24D11/00—Central heating systems using heat accumulated in storage masses
    • F24D11/002—Central heating systems using heat accumulated in storage masses water heating system
    • F24D11/005—Central heating systems using heat accumulated in storage masses water heating system with recuperation of waste heat
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
    • F28D21/00—Heat-exchange apparatus not covered by any of the groups F28D1/00 - F28D20/00
    • F28D21/0001—Recuperative heat exchangers
    • F28D21/0014—Recuperative heat exchangers the heat being recuperated from waste air or from vapors
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F27/00—Control arrangements or safety devices specially adapted for heat-exchange or heat-transfer apparatus
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06F—LAUNDERING, DRYING, IRONING, PRESSING OR FOLDING TEXTILE ARTICLES
    • D06F39/00—Details of washing machines not specific to a single type of machines covered by groups D06F9/00 - D06F27/00 
    • D06F39/30—Arrangements for energy recovery
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
    • Y02B40/00—Technologies aiming at improving the efficiency of home appliances, e.g. induction cooking or efficient technologies for refrigerators, freezers or dish washers
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S165/00—Heat exchange
    • Y10S165/909—Regeneration

Definitions

  • the present invention relates to a method of controlling an energy recovery system to achieve an increase of the statistical average system recovery efficiency, said system including at least one fluid accumulator tank and at least one heat exchanger for waste process fluid or gas.
  • waste heat may be recovered from process fluids and gases and transferred to other fluids, often water, this latter fluid being consumed in processes and/or used as a circulating heat carrier to transfer heat to other processes and for space heating.
  • industries having this type of recovery system e.g. the textile industry, the laundry industry, the food industry, etc., great variations occur over time in the amounts and temperatures of the waste heat emitting process fluids and gases, as well as in the momentary demand for new process fluid and/or recovered heat.
  • An object of the invention is to provide an improved automatic method to control an energy recovery system, such that the system recovery efficiency as defined above is maximized.
  • FIG. 1 is a schematic representation of a thermal energy recovery system according to the present invention
  • FIG. 2 is a graph of the regulation of the valve versus size of the tank in the system of FIG. 1;
  • FIG. 3 is a graph of tank temperature versus fluid level.
  • FIG. 1 shows schematically a system for the recovery of thermal energy from waste process fluids and gases.
  • reference numerals 1 and 2 designate machines in a first group of waste process fluid emitting machines in an industry, e.g., a textile industry, a laundry industry, a food industry, etc., which machines emit waste process fluids of different and varying temperatures, said process waste fluids being emitted either continuously or discontinuously (batchwise).
  • Reference numerals 3 and 4 designate machines in a second group of waste process gas emitting machines 3 and 4, which are operated either continuously or intermittently and at different and varying temperatures. Very often large variations of the enthalpy of the process gases will occur due to variations of water vapor content, such as in exhaust gases from industrial driers.
  • the number of machines 1, 2 or 3, 4 can be varied and is not limited to the number shown in the drawing.
  • waste process fluids emitted from the machines 1 and 2 are selected in such a way that at each moment only waste fluids having a temperature in excess of a reference temperature TR1 are admitted via a line 5 to a first waste process fluid collecting accumulator tank 6, whereby the reference temperature TR1 is an analytical function of both the temperature and the volume of the fluid already accumulated in said first accumulator tank 6. Waste fluids having temperatures below said reference-value are fed directly to a waste fluid outflow 7.
  • the waste fluid collected in the first accumulator tank 6 is conducted to a cleaning device 8 by means of a pump 9.
  • the waste process fluid which has been passed through said cleaning device is fed therefrom to a first beat exchanger 10.
  • the selection of waste process fluids conducted to the first accumulator tank 6 from the first group of machines 1 and 2 is affected by a first control device 11. Hence, the temperature of the fluid in the first accumulator tank 6 and the volume of the fluid are measured and registered in the first control device 11 and the choice whether to open valves 12 and 13 to conduct said waste process fluid to the first accumulator tank 6 is based on these measurements.
  • the first accumulator tank 6 has a spillway line 14, which is connected to the waste fluid outflow 7.
  • a second control device 15 is used to open a valve 16 on a line 17 leading from the cleaning device 8 through the primary side of the first heat exchanger 10 such that the flow through valve 16 is a function of the volume of the waste process fluid in the first accumulator tank 6.
  • the valve 16 is fully opened when the first accumulator tank 6 is full and is closing gradually as the volume of the fluid in the first accumulator tank 6 is decreasing, such that the valve is fully closed at zero fluid level.
  • FIG. 2 shows the regulation of the valve 16 as a function of the size of the accumulator tank 6.
  • Curve 1 is the regulation of the tank 6 if its size is small and curve 2 if the size of the tank 6 is large, where
  • H the fluid level (percent of maximum level) in the first accumulator tank 6
  • the waste process fluid from the cleaning device 8 is conducted through the primary side of said first heat exchanger 10 and further to the waste fluid outflow 7.
  • a cooling fluid is conducted through the secondary side of said heat exchanger 10 by means of a pump 19 to a second accumulator tank 20.
  • a valve 21 is provided, which is controlled by a third control device 22, said valve 21 being controlled with regard to a parameter being a function of both the flow rate through the primary side of the heat exchanger 10 and of the fluid volume in the second accumulator tank 20.
  • the fluid in the second accumulator tank 20 is thereafter conducted to consumers.
  • These consumers can of course be the group of machines 1 and 2 from which the waste process fluids are emitted or other machines requiring process fluids.
  • the waste process gas flows admitted to the second heat exchanger 25 are selected by a control device 38 via dampers 35 and 36 such that at each moment only waste gas flows having a temperature in excess of a reference temperature TR2 are admitted to the second heat exchanger 25, whereby the reference temperature TR2 is an analytical function of both the temperature of the fluid already accumulated in the second accumulator tank 20 and the volume and/or the temperature of the fluid already accumulated in a third accumulator tank 30.
  • the waste process gas leaving the second heat exchanger 25 may be led to a third heat exchanger 37 to heat another fluid, such as fresh water. Also, the waste process gas not admitted to the second heat exchanger 25 may be merged with the gas cooled in the heat exchanger 25 before entering the third heat exchanger 37.
  • the fluid in the second accumulator tank 20 will also, in many cases, be led, via a pipeline 24, through the second heat exchanger 25 by means of a pump 26.
  • a pump 26 Through the primary side of the second heat exchanger 25 waste process gas emitted from the second group of machines 3 and 4 is conducted via a duct 27 by means of a fan 28.
  • the fluid passing through the secondary side of said heat exchanger 25 is conducted via a pipeline 29 to said third accumulator tank 30.
  • the flow of fluid from the second accumulator tank 20 to the third accumulator tank 30 is controlled by means of a fifth control device 31, adapted to operate on a valve 32, such that the flow is determined by a parameter TR3 being a function of both the volume of the fluid already accumulated in the third accumulator tank 30 and a reference temperature level set between the temperatures of the gas flow to the secondary side of said second heat exchanger 25 and of the feed fluid flow to the primary side of said heat exchanger.
  • the first accumulator tank 6 is only partly filled with fluid of, e.g., 60° C., or is totally filled with fluid of, e.g., 35° C. due to heat losses (the temperature often decreases in the accumulator tank some degrees below the selecting temperature), it is a loss to conduct a fluid which does not fulfill the above described selecting criteria to said outflow.
  • TR1(H) may accordingly be a slowly increasing function of the level H, implying that, when the waste fluid volume in the first accumulator tank 6 is small, even rather cool waste fluid contributions will be accepted to it.
  • TR1(H) when the first accumulator tank 6 is small in relation to the average supply rate, TR1(H) must be a much more sensitive (faster increasing) function of H.
  • H max maximum level in the first accumulator tank 6
  • T1 temperature of the cold feed fluid supply
  • the parameter n can be adjusted to give optimal waste fluid selection from a recovery point of view.
  • n n>>1.
  • H1 the level in the first accumulator tank 6
  • H2 the level in the second accumulator tank 20.
  • the cleaning device 8 and the pumps 9 and 18 are large, the energy in the waste fluid can immediately be recovered with high efficiency and transferred to clean fluid which will be stored in the second accumulator tank 20, whereby the dependence on the first accumulator tank 6 is reduced.
  • the pumps and the cleaning device it is, however, normally more economic to size the first accumulator tank 6 such that its volume is equal to a few times the average flow per hour of waste water.
  • T0 the temperature of the waste fluid before selection
  • TR1(H) the variable reference temperature as a function of the storing capacity of the accumulator tank 6
  • the average magnitudes of the flow rates on the primary and on the secondary sides of the heat exchanger 10 shall have a given relationship (correlation).
  • the heat exchanger 10 should be utilized as continuously as possible.
  • the heat recovered as well as the process fluids should be accumulated as efficiently as possible in order to level out the considerable load variations during a day.
  • the drawing again can be used.
  • the cleaning device 8 and the valve 16, for the sake of simplicity will be left out of consideration, and it is assumed that the pump 9 feeds waste fluid from the first accumulator tank 6 directly into the first heat exchanger 10.
  • the pump 9 is equipped with a safety device (not shown) which stops the pump 9 when a predetermined low level is reached in the first accumulator tank 6.
  • the supply rate of waste fluid to the first accumulator tank 6 is varying greatly during a twenty-four hour period. So, the instantaneous value of the supply rate can be ten times the average value of the supply rate during a twenty-four hour period. The hourly mean value of the supply rate often varies by a factor of three to four times the twenty-four hour average value.
  • the flow rate on the primary side of the heat exchanger 10 should be held constant and equal to the twenty-four hour average supply rate to the accumulator tank 6 from the first group of machines 1 and 2. This would permit a uniform utilization of the heat exchanger 10. In practice, this is seldom possible due to the finite size of the first accumulator tank 6.
  • the volume of the accumulator tank 6 is 30 m 3 and the average value of the flow rate to the accumulator tank 6 over a twenty-four hour period is 30 m 3 /h. Frequently occurring one-hour average values of the supply rate are thus 60-90 m 3 /h.
  • the pump 9 must have a capacity of 75-90 m 3 /h.
  • the heat exchanger 10 will be utilized in a very discontinuous way.
  • the heat exchanger 10 is utilized only during 33-40 percent of the total time, but with a high load of waste fluid, 75-90 m 3 /h. As a result of this discontinuity, the recovery efficiency is lower as compared to the efficiency which would be obtained with the same heat exchanger at a constant flow rate of 30 m 3 /h.
  • the flow through the primary side of said heat exchanger 10 is, according to the present invention, controlled such that said flow rate is allowed to increase when the level in the accumulator tank 6 is raising and to decrease when the level is sinking.
  • a cleaning device When a cleaning device is used according to the drawing, it may be suitable (see the Swedish Pat. No. 8006389-4 by Applicant) to return to the first accumulator tank 6 the fluid, which is fed to said cleaning device, but which is not transported further by pump 18 through the heat exchanger 10.
  • the volume capacity of the pump 9 can without disadvantage be chosen large, and the pump 9 will then work continuously as long as fluid is present in the accumulator tank 6 (the pump 9 is stopped by means of said safety device when the level in the first accumulator tank 6 is approaching zero).
  • valve 16 shall in this case close until a balance is reached between supply and the outflow rates, respectively.
  • control of the flow through the heat exchanger 10 is provided by means of the throttle valve 21 or, as an alternative, by controlling the rotation speed of the pump 19.
  • a further improvement is obtained by continuously varying the set or reference value of the flow ratio between the secondary and the primary flows, as a function of the level in the second accumulator tank 20, thereby, taking into consideration the remaining accumulating capacity in the accumulator tank 20.
  • the set value is decreased as a function of the level, thereby decreasing the flow to the second accumulator tank 20.
  • the set value is increased, thereby increasing the flow to the accumulator tank 20.
  • the flow to the low temperature accumulator 20 in a system with accumulation at two temperature levels can be controlled by a flow ratio or described above.
  • the ratio control is overridden in the cases when too low or too high a level in the accumulator tank 20 occurs.
  • the valve 21 In the former case the valve 21 is forced to open (or is the pump 19 forced to run with full speed) independently of the instantaneous flow rate value. In the latter case the valve 21 is forced to close (or the pump 19 is stopped).
  • the set value for the ratio of the flow rates should be chosen such that the flow rate to the accumulator tank 20 is, on the average, equal to the flow rate therefrom, i.e., the long term mean value of the supply to the accumulator tank 20 is equal to the long term mean value of the output from the accumulator tank 20 without hitting the permissible maximum levels in the accumulator 20.
  • the intermediately stored fluid from the accumulator tank 20 or the fluid directly from heat exchanger 10 can be postheated by the heat exchanger 25 and stored in the accumulator tank 30.
  • the accumulator tank 30 may already be filled with fluid, i.e., the storing capacity is fully utilized, and which prevents utilization of the more valuable later waste heat flow to the primary side of heat exchanger 25.
  • the described system will comply with said criterium 5, for the optimal utilization of the available secondary storage capacity accumulator tanks 20 and 30 by controlling the flow rate q 5 such that a desired temperature (set temperature) is obtained by variation of the flow rate through the heat exchanger 25, such that the flow rate is decreased if the actual temperature (measured with a sensor) is below the set temperature and is increased if the actual temperature is above the set temperature, the set temperature being a function of the level in the accumulator tank 30. This level is measured with a level sensor, and controls the set temperature to the control device 31.
  • the set temperature is decreased, i.e., less heated fluid is accepted.
  • the above described system can be extended to apply to a system, in which the second accumulator tank 20 is omitted.
  • the pipe line from the heat exchanger 10 is connected directly to the heat exchanger 25 as shown by the dotted lines 39.
  • the third and fourth control devices 22 and 31 act together, and only one of the valves 21 and 32 is needed.
  • the second accumulator tank 20 as well as the pump 26 are disposed of.
  • alteration of the set value in relation to the level in the accumulator tank 30 is extended to comprise not only the set value BT5 to the control device 31, but also the set value BK2 to the control device 22.
  • the set values BK2 and BT5 are decreased, whereby a greater flow rate is allowed through the heat exchangers 10 and 25.
  • the set value control is only overridden when the level in the third accumulator 30 is low or high (the connection between the set value BT5 and the level in the accumulator tank 30 can be chosen such that the valve 32 is totally closed when the tank is full, whereby overriding of the set value control at high level is not required).
  • on-line calculation and on-line computer control are required, taking into consideration waste heat supply and quantity, demand of process fluid and heat, patterns of consumption, accumulator tank sizes and the actual characteristics of the heat exchangers (i.e. the heat transferring capacities as kW/°C. of logarithmic mean temperatures at different flow rates and temperatures on the primary and the secondary sides of the heat exchangers).

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Textile Engineering (AREA)
  • Control Of Temperature (AREA)
  • Heat-Pump Type And Storage Water Heaters (AREA)
US06/730,557 1984-05-07 1985-05-06 Method of controlling an energy recovery system Expired - Fee Related US4742865A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP84850146A EP0160775B1 (de) 1984-05-07 1984-05-07 Verfahren zur Kontrolle eines Energierückgewinnungssystems
EP84850146.6 1984-05-07

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Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2008138308A1 (de) * 2007-05-11 2008-11-20 Aweco Appliance Systems Gmbh & Co. Kg Haushaltsmaschine, insbesondere geschirrspülmaschine mit wärmetauscher
US20100089552A1 (en) * 2008-10-15 2010-04-15 Vu James I Heat energy recovery system
WO2016020771A1 (en) * 2014-08-08 2016-02-11 Albini Energia S.R.L. Heat recovery system from industrial machines in particular for textile processes
CN105793638A (zh) * 2013-07-25 2016-07-20 丹伯里资源公司 降低流量变化和增压二氧化碳的方法和装置
US20190078570A1 (en) * 2017-09-14 2019-03-14 Milton Roy, Llc Automatic Initiation of Priming Sequence for Metering Pumps
US11150029B1 (en) * 2018-02-23 2021-10-19 United States Of America As Represented By The Secretary Of The Air Force Thermal management using endothermic heat sink
DE102023134265A1 (de) * 2023-12-07 2025-06-12 Jürgen Krämer Wäschereisystem mit optimierter Nutzung eingebrachter Energie

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DE4219164A1 (de) * 1992-06-11 1993-12-16 Jacob Weitman Verfahren und Vorrichtung zur Aufwandsminimierung von Anlagen zum Reinigen von und/oder Rückgewinnen von Wärme aus Abgasen und/oder Abwässern oder dergleichen Prozeßfluida
DE102006020003A1 (de) * 2006-04-26 2007-10-31 Herbert Kannegiesser Gmbh Verfahren zur Rückgewinnung der von Wäschereimaschinen abgegebenen Wärmeenergie
TWI497084B (zh) 2010-09-30 2015-08-21 Ismeca Semiconductor Holding 電性接點及測試平台
DE102011002721B4 (de) * 2011-01-14 2023-03-23 Krones Aktiengesellschaft Behälterreinigungsanlage
ES2394878B1 (es) * 2011-06-15 2014-07-21 Albert Puig Torrelles Dispositivo de aprovechamiento térmico

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US2713252A (en) * 1952-05-07 1955-07-19 Little Inc A Temperature control system
GB1108492A (en) * 1965-07-24 1968-04-03 Newton Robert Park Water heater
US3946802A (en) * 1973-10-09 1976-03-30 Rune Christenson Method and apparatus for heat recovery
FR2381257A1 (fr) * 1977-02-16 1978-09-15 David Jean Pierre Procede et dispositif pour la recuperation d'energie calorifique dans les eaux usees
DE2809989A1 (de) * 1978-03-08 1979-09-13 Maeueler E & A Gmbh & Co Verfahren zur waermerueckgewinnung aus waschwaessern einer flaschenabfuellstrasse
US4207752A (en) * 1978-09-06 1980-06-17 Michael Schwarz Method and apparatus for recovering heat from waste water
DE2947360A1 (de) * 1979-11-17 1981-05-21 Dieter Edelbert 6833 Waghäusel Mail Verfahren fuer die waermerueckgewinnung aus haushaltsabwaessern zur erwaermung von haushaltsabvwaessern zur erwaermung von haushaltsbrauchwasser oder waermerohr
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Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2008138308A1 (de) * 2007-05-11 2008-11-20 Aweco Appliance Systems Gmbh & Co. Kg Haushaltsmaschine, insbesondere geschirrspülmaschine mit wärmetauscher
US20100089552A1 (en) * 2008-10-15 2010-04-15 Vu James I Heat energy recovery system
CN105793638A (zh) * 2013-07-25 2016-07-20 丹伯里资源公司 降低流量变化和增压二氧化碳的方法和装置
US10066884B2 (en) * 2013-07-25 2018-09-04 Denbury Resources Inc. Method and apparatus for dampening flow variations and pressurizing carbon dioxide
CN110360454A (zh) * 2013-07-25 2019-10-22 丹伯里资源公司 降低流量变化和增压二氧化碳的方法和装置
WO2016020771A1 (en) * 2014-08-08 2016-02-11 Albini Energia S.R.L. Heat recovery system from industrial machines in particular for textile processes
US20190078570A1 (en) * 2017-09-14 2019-03-14 Milton Roy, Llc Automatic Initiation of Priming Sequence for Metering Pumps
CN109505761A (zh) * 2017-09-14 2019-03-22 米顿罗有限责任公司 计量泵的灌注程序的自动起动
US11150029B1 (en) * 2018-02-23 2021-10-19 United States Of America As Represented By The Secretary Of The Air Force Thermal management using endothermic heat sink
DE102023134265A1 (de) * 2023-12-07 2025-06-12 Jürgen Krämer Wäschereisystem mit optimierter Nutzung eingebrachter Energie

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